CAMISEA

OPERATIONS

August, 2007

CAMISEA
Operations Performance

INDEX
OPERATIONS EFFECTIVENESS COMPONENTS
(KPIs)
OVERALL EQUIPMENT EFFECTIVENESS (OEE)
MALVINAS OEE
PISCO OEE
RELIABILITY
BENCH
SAFETY RECORDS

OPERATIONS EFFECTIVENESS
COMPONENTS (KPIs)
Utilization / Production / Throughput (Gas)
Availability
Reliability
Yield / Recovery (C3)
(As a rule of thumb, World-class performers will only have losses
of between 1.5 % to 2 % for all indicators)
KPIs : Key Performance Indicators

Overall Equipment Effectiveness

(OEE)
Objective method to link three performance indicators:
Availability
Throughput
Yield / Recovery

Overall Equipment Effectiveness

(OEE)
Can be expressed simply:
OEE = Yield x Throughput x Availability
The Maximun Theoretical

World Class - OEE > 85%

Overall Equipment Effectiveness (OEE)

OEE = Availability
(Plant Unit)
Hr Operatives
Vs

Throughput

Recovery (C3)

(Gas)
Actual Throughput
Vs

Hr Calendars

Best Demonstrated
Rate (BDR)

(96 %)

(500 MMSCFD)

Actual yield (C3)

Vs
Max Theoretical yield
(for BDR)
(97.2%)

Malvinas Operations
Plant Level
Estabiliz.

Unit Level

Equim. Level nC 1, 2, 3

Overall:

Equipment:

Effectiveness:

OEE = A x P x R

Cry I

Unit Level

Equim. Level; TC I
TEx I

Unit Level

Cry II
Equim. Level; TC II
TEx II

Asset Plant
Level

Availability

Production

Recovery (yield)

PISCO OEE
PLANT LEVEL / OVERALL OEE
LPG FRACTIONATION UNIT

OEE 1 (Fract)

TOPPING UNIT

OEE 2 (Topp)

OVERALL OEE = (OEE 1 + OEE 2)

2
PISCO
AxTxY AxTxY
Fract
Topp

OEE 1 FRACTIONATION UNIT

THROUGHPUT
Actual Throughput
Vs
NGL received from Malvinas

OEE 1 FRACTIONATION UNIT

RECOVERY (Yield) C3/C4
Actual Yield
C3

Vs
Design Yield (97.93% Vol)

Actual Yield
C4

Vs
Design Yield (99.21 % Vol)

OEE 1-2 FRACTIONATION AND TOPPING UNITS

AVAILABILITY
Hs Operatives (Hs Run)
Vs
Hs Calendars

OEE 2 TOPPING UNIT

THROUGHPUT
Actual Throughput
Vs
(NGL received from Malvinas) x 0.54

0.54 = design fraction of condensate in NGL from Malvinas

Reliability
Unplanned downtime (Reactive Maintenance)
Maintenance Backlog

Hs Operations
Vs
Hs Operations + Hs TMR
(TMR: Total Maintenance Reactive)
(Reliability; World Class performers > 98%)

RELIABILITY 2006
MALVINAS 99%
Control

PISCO

(Average of 24 main equipments:

Turbocompressors,Turbogenerators,
Turboexpanders, Pumps,
System)

97.8% (Average of 20 main equipments:

Turbogenerators, Pumps, Control
System, Generators, Compressors)

Malvinas Operations OEE 2006 Plant Level

Malvinas Operations OEE 2007

Plant Level

Pisco Operations OEE 2006 Plant Level

Pisco Operations OEE 2007

Plant Level

BENCH

The Reliability Involves Four Stable Operating Domains

(Source: Ledet Enterprises, Houston Texas)

OEE Mal
0.94

OEE Pis
0.93

Maintenance Cost Vs. Production Reliability

2007

Malvinas
Pisco

Maintenance Cost vs. Production reliability. Plants with the best overall equipment
effectiveness tend to have the lowest maintenance cost and use systematic failure
elimination, profit-centered maintenance and performance contracting.

Data from the 1998 and 2000 Solomon Associates Inc. surveys of the participating North and South
American refining companies

As a rule of thumb,
World-class performers will only have losses of between
1.5 % to 2 % for all indicators
world-class performers are operating at > 85% of BDR
Reliability; World Class performers > 98%
Availability: world class performers > 96 %
Unavailability both timing and duration must be
predictable. There must be no surprises

References
OIL & GAS JOURNAL / May 9, 2005
OEE Method Improves Condition Based Maintenance
Aspen Technology Inc. , Houston Texas

HYDROCARBON PROCESSING / January 2005

Achieving World-Class Operating Performance
Polaris Veritas Inc. , Houston Texas

Data from the 1998 and 2000 Solomon Associates Inc.

surveys of the participating North and South American
refining companies - Toward World Class Plant Availability
Tom Ratajczak UOP LLC

SAFETY RECORDS

SAFETY MALVINAS

SAFETY MALVINAS

SAFETY PISCO

SAFETY PISCO

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